Professional Documents
Culture Documents
Introduction
Basic mechanical, hydraulic and electrical TEREX RL4000/TML-4000 Operator's Manual .. 116692
skills are required to perform most procedures. First Edition
However, several procedures require specialized TEREX RL4000/TML-4000 Service Manual ....... 116694
skills, tools, lifting equipment and a suitable First Edition
workshop. In these instances, we strongly
recommend that maintenance and repair be TEREX RL4000/TML-4000 Part's Manual .......... 116693
performed at an authorized TEREX dealer First Edition
service center. Perkins Operations Manual ................................ 131661
Printed in U.S.A.
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the appropriate Operator's
Manual on your machine will result in death or
serious injury.
SAFETY RULES
Table of Contents
Introduction
Important Information - Introduction ................................................................... ii
How to Read Your Serial Number ..................................................................... iii
Parts Stocking List ............................................................................................ ix
How to Order Parts ........................................................................................... xi
Service Parts Fax Order Form ......................................................................... xii
TABLE OF CONTENTS
Machine Information
Model
Serial Number
Date of Purchase
Phone Number
All backordered parts will be shipped when available via the same ship method as the original order
unless noted below:
o Ship complete order only - no backorders
o Ship all available parts and contact customer on disposition of backordered parts
o Other (please specify)
REV A
Specifications
Model - RL4000 & TML-4000
SPECIFICATIONS REV A
RL4000
REV A SPECIFICATIONS
TML-4000
SPECIFICATIONS REV A
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
REV A
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operators manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operators manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
REV A
Maintenance Schedules
Kubota Lubrication and Maintenance Service Intervals
Every Every Every Every Every Every Every Every
Every 50 Every
ITEM Hours
100 200 400 500
Year
800 1500 3000 Two
Hours Hours Hours Hours Hours Hours Hours Years
Check of fuel pipes and clamp bands
Check engine oil and coolant level
Cleaning of air cleaner element
Check of battery electrolyte level
Check of fan belt tightness
Check of radiator hoses and clamp
bands
Check of intake air line
Replacement of oil filter cartridge
Replacement of fuel filter cartridge
Removal of sediment in fuel tank
Cleaning of water jacket (radiator
interior)
Replacement of fan belt
Replacement of air cleaner element
Check of damage in electric wiring
and loose connections
Check of valve clearance
Check of fuel injection nozzle injection
pressure
Check of turbo charger
Check of injection pump
Check of injection timer
Change of radiator coolant (L.L.C.)
Replacement of battery
Replacement of radiator hoses and
clamp bands
Replacement of fuel pipes and clamp
bands
Replacement of intake air line
*Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the
information in the manufacturer's manual differs from that in this manual the manufacturer's manual
should take precedence.
*Refer to the manufacturer's manuals for detailed maintence intervals and instructions. If the
information in the manufacturer's manual differs from that in this manual the manufacturer's manual
should take precedence.
REV A
REV A
Troubleshooting
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Electrocution hazard. Exposure to
the repair of this machine.
electrically charged circuits could
Immediately tag and remove from service a result in death or serious injury.
damaged or malfunctioning machine. Remove all rings, watches and
other jewelry.
Repair any machine damage or malfunction
before operating the machine. Electrocution hazard. Attempting
to sevice the machine before the
Unless otherwise specified, perform each capacitors are fully discharged will
repair procedure with the machine in the result in death or serious injury.
following configuration:
Machine parked on a firm, level surface. High voltage. Exposure to
electrical wires or electrical current
Wheels chocked. will result in death or serious
Toggle switch in off position. injury. Remove all rings, watches
and other jewelry. Turn off all
power when not needed for
testing. Use extreme caution when
working with high voltage electrical
components.
Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.
REV A
Troubleshooting Guide
The engine/generator set is tested and set at the factory for proper operation in the field. These units
should never require additional adjustments in the field. If needed, adjustments should only be made by a
qualified service technician, otherwise the manufacturers warranty may become void.
REV A TROUBLESHOOTING
TROUBLESHOOTING REV A
REV A TROUBLESHOOTING
IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT, SHUT IT DOWN
IMMEDIATELY! HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN.
THIS ENGINE/GENERATOR SET IS FACTORY INSTALLED, TESTED, AND SET FOR FIELD
OPERATION. ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER
ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE
COVERED BY YOUR MANUFACTURERS WARRANTY AND WILL ALSO VOID THE
MANUFACTURERS WARRANTY ON THIS PARTICULAR UNIT. IF YOU CAN NOT REACH YOUR
LOCAL DEALER, CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1-800-433-3026.
REV A
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
DC Wiring, Kubota
Drawing #116814 REV A
MH Light Fixture
Drawing #2985A REV A
1000 MH Ballast
REV A Drawing #2986
Warning Warning
Battery post terminals and related The exhaust from this product
accessories contain lead compounds, contains chemicals known to
chemicals known to the State of the State of California to
California to cause cancer cause cancer, birth defects
and other reproductive harm. or other reproductive harm.
Towing Checklist
(Use at each stop)
Before Towing Towing hitch is properly secured to tow vehicle
Safety chains (if required) are properly attached
and secure (chains are crossed below hitch)
All lights are connected and working
Tires are properly inflated